OK Ive been wanting to increase the range of the 950 for a while now and it seemed the only way to go was the tanker replacement fuel tanks from safari - that 40+ litres is sure tempting but the tank movement has me a little concerned not to mention some reports of cracking windscreens. Other than that there are those from a couple of South African companies but after hearing and seeing their fit and finish ive decided on rallye aux tanks.
Now seeing as KTM didnt offer a version for sale to the public or the tanks as a part I decided to make my own. Thanks to barbasma for the detailed photos of Meonis R950 - a lot of very interesting detail to be seen if your looking.http://picasaweb.google.com/KTMPETE/950RallyeTanks#

So where are we - the GPR has replaced the stock headers/X pipe and cans saving 7 kg. Next was the seat base and tail light/fender unit (2.4kg) leaving the subframe - which is obviously different to the rally's. The link to picasa shows where Im up to atm. Next step is fairing and finishing before moulding - so other than the great ideas Ive already been given by a few inmates here does anyone have any other ideas or bits that ive forgotten to "build into" them???
Ive done the infills (today) inboard of the frame and cutouts for the chain guars/swingarm/brake calliper/etc. Other than that Im thinking of the fillers and petcocks.

Hi Deadly
Yep a couple of extra pics of the recessing to clear the swingarm/chain guide and disc caliper. The rhs tank looks off - but that was because of the midpipe bracket pushing it out.
...and there is a pic looking straight down showing the rh tank infill next to the shock.

...and yep - the rear tanks are much narrower than the front @450mm wide - or 18" depending where you live. Also making the seat base incorporating the rear fender and twin tail lights.

Greetings,
Why is the Adv. Rallye tank setup so hard to come by? There seems to be plenty of interest, so why hasn't someone stepped up and offered a complete, bolt-on kit?
Or have they, and I've just missed it?

Greetings,
Why is the Adv. Rallye tank setup so hard to come by? There seems to be plenty of interest, so why hasn't someone stepped up and offered a complete, bolt-on kit?
Or have they, and I've just missed it?

Having looked at some of the others made (I like the canadian one the best) none were able to be easily reproduced but frp allows you certain freedom in this regard. Ally with the welding and bending is more time consuming I guess but some products are truly brilliant.

How would you go about mass producing a piece like this, do you lay up two halves in separate molds and then join them together somehow? Is there any issue of delamination if you fit the ground sometimes?

I have only seen the big tanks done with rotomolding plastic, or if using FRP the lost foam method which is obviously too time consuming for mass production.

Yep - 2 halfs joined. Wont be a problem with delamination given the joining method and products used.
Not sure mass production is required atm - but if so Id investigate rotomoulding but that is a looooonnngggg way down the track. Yes I will mould it for manufacturing integrity and replacement but its just a custom part for me atm.

Thats the plan so no other tools will need to be carried to R+R them other than whats in the baggie already. Ive got some OEM 690 Rallye tanks coming over this week to have a look at to compare/weigh which should be interesting.
Unfortunately the fab is on the go slow atm - doing a CF bashie to protect the low header - cant find one in CF that'll suit or mount up to the OEM points.

I know, I know. Aust safari is just around the corner and there a couple of things I have to make for some friends.
Gas caps - what are your thoughts, keep it original looking or go flush mount like the main tanks?